ESD5500E SERIES

SPEED CONTROL tlNIT

PRODUCT

INFORMATION

BULLETIN

APPLICATION INFORMATION

The ESD5500E Series speed control unit is rugged enough to be placed in a control cabinet or engine mounted enclosure with other dedicated control equipment. lf water, mist, or condensation may come in contact with the controlller, it should be mounted vertically. This will allow the fluid to drain away from the speed control unit.

Extreme heat should be avoided.

WARNING

An overspeed shutdown device, independent of the governor system, should be provided to prevent loss of engine control which may cause personal injury or equipment damage. Do not rely exclusively on the governor system electric actuator to prevent overspeed. A secondary shutoff device, such as a fuel solenoid must be used.

WIRING

Basic electrical connections are illustrated in Diagram 1. Actuator and battery connections to Terminals A, B, E, and F should be #16 AWG (1.3 mm sq.) or !arger. Lang cables require an increased wire size to minimize voltage drops.

The battery positive ( +) input, Terminal F, should be fused for 15 amps as illustrated.

Magnetic speed sensor connections to Terminals C and D MUST BE TWISTED AND/OR SHIELDED for their entire length. The speed sensor cable shield should ideally be connected as shown in Diagram 1 . The shield should be insulated to insure no other part of the shield comes in contact with engine ground, otherwise stray speed signals may be introduced to the speed control unit. With the engine stopped, adjust the gap between the magnetic speed sensor and the ring gear teeth. The gap should not be any smaller than 0.020 in. (0.45 mm). Usually, backing out the speed sensor 3/4 turn alter touching the ring gear tooth will achieve a satisfactory air gap. The magnetic speed sensor voltage should be at least 1 VAG RMS during cranking.

ADJUSTMENTS

ßefi:>re Starting Engin_e

Check to insure the GAIN and ST ABILITY adjustments, and if applied, the external SPEED TRIM CONTROL are set to mid position.

Present the ESD5500E as follows: STARTING FUEL.. ................. FULL CW (Maximum Fuel) SPEED RAMPING ................ FULL CCW (Fastest)

Start Englne The speed control unit governed speed setting is factory set at approximately engine idle speed. (1000 Hz., speed sensor sigial) Crank the engine with DC power applied to the gover­nor system. The actuator will energize to the maximum fuel position until the engine starts. The governor system should control the engine at a low ldle speed. lf the engine is unstable a1ter starting, turn the GAIN and STABIUTY adjustments counterclockwise until the engine is stable.

Goyemor Speed Setting

The governed speed set point is increased by clockwise rctation of the SPEED adjustment control. Remote speed adjustment can be obtained with an optional 5K Speed Trim Control. (See Diagram 1.)

Govemor Performan@

Once the engine is at operating speed and at no load, the following govemor performance ocljustment can be made.

A. Rotate the GAIN adjustment clockwise until instabilitydevelops. Gradually move the adjustment counterclockwiseuntil stability returns. Move the adjustment one qivision furthercounterclockwise to insure stable performance.

B. Rotatethe STABILITY adjustment clockwise until instabil­lty develops. Gradually move the adjustment counterclock­wise until stability returns. Move the adjustment one divisionfurther to insure stable perlormance.

lf instability cannot be corrected or further pe:formance im­provements are required, refer to the section on SYSTEM TROUBLESHOOTING.

Startlng Fuel Adjustment The engine' s exhaust smd<e at start-up can be minimized by completing the following adjustments.

1. Place the engine in idle by connecting Terminals M & G.

2. Adjust the IDLE speed for as low a speed setting as theapplication allows.

3. Adjust the STARTING FUEL CCW until the engine speedbegins to fall. lncrease the STARTING FUEL slightly so thatthe idle speed is returned to the desired level.

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4. Stop the engine.

One of two methods of operation for the ES05500 may

now be selected.

METHOD 1: Start the engine and accelerate directly to the operating speed (Gen Sets, etc.).

or METHOD 2: Start the engine and control at an idle speecl for a period of time prior to accelerating to the operating speed. This method separates the starting process so that each may be optimized for the lowest smoke emissions.

METHOD 1 Remove the connection between T erminals M & G . Start the engine and adjust the SPEED RAMPING for the least smoke on acceleration from idle to rated speed. ff the starting smoke is excessive, the STARTING FUEL may need to be adjusted slightly CCW. ff the starting time is too long, the STARTING FUEL may need to be adjusted slightly CW.

METHOD 2

Replace the connection between Terminals M & G with a switch, usually an oil pressure switch. Start the engine. ff the starting smoke is excessive, the STARTING FUEL may need to be adjusted slightly CCW. ff the starting time is too long, the STARTING FUEL may need to be adjusted slightly CW.

When the switch opens, adjust the SPEED RAMPING for the least amount of smoke when accelerating from idle speed to rated speed.

ldle Speed Setting

lf the IDLE speed setting was not adjusted as detailed in "Starling Fuel Adjustment" section, then place the optional external selector switch in the IDLE position. The idle speed set point is increased by clockwise rotation of the I D LE adjustment control. When the eng1ne is at idle speed, the speed control unit applies droop· to the governor system to insure stable operation.

Speed Droop Operation

Droop is typically used for the paralleling of engine driven generators.

Place the optional external selector switch in the DROOP position, DROOP is increased by clockwise rotation of the DROOP adjustment control. When in droop operation, the engine speed will decrease as engine load increases. The percentage of droop is based on the actuator current change from engine no load to full load. A wide range of droop is available with the internal control. Droop level requirements above 1 0% are unusual.

lf droop levels experienced are higher or lower than those required, contact the factory for assistance.

After the droop level has been adjusted, the rated engine speed setting may need to be reset. Check the engine speed and adjust the speed setting accordingly.

Accessory Input

The AUXilary Terminal N accepts input signals from load sharing units, auto synchronizers, and other governor system accessories, GAC accessories are directly connected to this terminal. lt is recommended that this connection from acces­sories be shielded as it is a sensitive input terminal.

lf the auto synchronizer is used alone, not in conjunction with a load sharing module, a 3 M ohm resistor should be con­nected between Terminals N and P. This is required to match the voltage levels between the speed control unit and the synchronizer.

When an accessory is connected to T erminal N, the speed will decrease and the speed adjustment must be reset.

When operating in the upper end of the control unit frequency range, a jumper wire or frequency trim control may be required between Terminals G' and J. T his 1ncreases the frequency range of the speed control to over 7000 Hz.

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Accessory Supply

The + 10 volt regulated supply, Terminal P, can be utilized to provide power to GAC governor system accessories. Up to 20 ma of current can be drawn from this supply. Ground reference is Terminal G . Cautlon: a short circuit on this terminal can damage the speed control unit.

Wide Range Remote Variable Speed Operation

Simple and effective remote variable speed can be obtained with the ESD5500E Series control unit.

A single remote speed adjustment potentiometer can be used to adjust the engine speed continuously over a specific speed range. Select the desired speed renge and the corresponding potentiometer value. (Refer to TABLE 1.) lf the exact range cannot be found, select the next higher range potentiometer. An additional fixed resistor may be placed across the potenti­ometer to obtain the exact desired range. Connect the speed range potentiometer as shown in Diagram 2.

To maintain engine stability at the minimum speed setting, a small amount of droop can be added using the DROOP adjustment. At the maximum speed setting the governor performance will be near isochronous, regardless of the droop adjustment setting.

Contact the factory for assistance rf difficulty is experienced in obtaining the desired variable speed governing performance.

TABLE 1- Variable Speed Range Potentiometer Yafue Speed Range Potentiometer Value

900 Hz. 1K 2,400 Hz. 5K 3,000 Hz. 1 OK 3,500 Hz. 25K 3,700 Hz. 50K

DIAGRAM 2.

G J

cw

K

·select Proper Potentiometer Value from Table 1.

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